Honeywell CD3000M-1PH User Manual Download

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Honeywell

CD3000M-1PH from 125A to 700A

User’s Manual

www.honeywell.com/imc

10. Maintenance

10.1

Trouble Shooting

Small problems sometimes can be solved locally with the help of the below tab of trouble shooting.
If you don’t succeed, contact us or your nearest distributor.

Symptom

Indication on

front unit

Possible reasons of the symptom

Actions

Green LED is

always light

off.

No voltage auxiliary power

supply to terminals 1-3 (see

wiring diagram).

Give auxiliary voltage supply

to terminals 1-3.

Green LED

(PW) light on

and green LED

(ON) in light off

condition.

No input signal.

Reversed polarities of input

signal.

Reset contact in open condition

(see wiring diagram).

Provide to give input signal.

Reverse the input signal

polarity.

Make link on reset terminals.

Thyristor unit

doesn’t go in

conduction with

input signal.

Green LED

(PW) in light

on condition

and green LED

(ON) in light on

condition.

Fuse failure.

Load failure.

Load connection interruption.

Thyristor faulty and always in

open circuit.

With HB option the yellow led

(HB) in light on condition.

Substitute the fuse.

Repair the load.

Provide to repair the wiring.

Substitute the faulty

thyristor.

Check the load.

Load current

flows also with

no input signal.

Green LED

(ON) always in

light off

condition.

Short circuit on thyristor. If

there is HB circuit the red LED

(SC) is light on.

Substitute the thyristor.

Check that load is not in

short circuit.

Current flows at

nominal value

but yellow LED

(HB) in light on

condition.

Yellow HB in

light on

condition.

HB circuit not tuned.

Current transformers not

properly wired (if are external

to CD3000).

Push CAL button in front unit

to start HB calibration

procedure.

Control current transformers

wiring and Push CAL button

in front unit to start HB

calibration procedure.

Red LED (SC) is

lighted also if

current is at

nominal value.

Red LED in

light on

condition.

HB circuit not properly tuned.

Push CAL button in front unit

to start HB calibration

procedure.

Thyristor unit

doesn’t work

properly.

Wrong input signal selection.

Wrong input signal calibration

(out of range).

Auxiliary voltage supply out of

limits.

Control input signal setting.

Repeat input calibration

procedure.

Verify the auxiliary voltage

supply.

Summary of Contents for CD3000M-1PH

Page 1: ...EN1I 6307 USER S MANUAL Rev 12 2004 CD3000M THYRISTOR UNIT From 125A to 700A ...

Page 2: ...User s Manual CD3000M 1PH from 125A to 700A Honeywell 1 www honeywell com imc ...

Page 3: ...rmation 10 4 1 Identification of the unit 10 4 2 Installation 10 4 3 Dimensions 11 4 4 Fixing Holes 12 5 Wiring Instructions 13 5 1 Removing the cover 13 5 2 Cabling detail 16 5 3 Wiring connection 19 5 4 LED Status Table 20 6 Start up 21 6 1 Auxiliary supply 22 6 2 Heater Break Alarm 25 6 3 Delay triggering option 28 7 Thyristor firing mode 29 7 1 Zero Crossing ZC 29 7 2 Single Cycle SC 29 7 3 Bu...

Page 4: ...mc 9 1 Physical requirements 35 9 2 ModBus RTU protocol 35 9 3 Word parameters 40 9 4 Thyristor unit Configuration 45 9 5 Address Configuration 49 10 Maintenance 52 10 1 Trouble Shooting 52 10 2 Repairing procedure 53 10 3 Fans 53 10 4 Servicing 53 10 5 Warranty conditions 53 ...

Page 5: ...ecure that access to thyristor unit is only permitted to specialized personnel the authorised personnel must read this manual before to have access to the unit the access to the units must be denied to unauthorized personnel Important warnings attention Local regulations regarding electrical installation should be rigidly observed Safety regulations must be rigidly observed Don t bend components t...

Page 6: ...plied by dedicated voltage supply for all electronic circuit but not in parallel with contactor s coil solenoids and other inductive or capacitive loads It s recommended to use a shielded transformer Electromagnetic compatibility compatibilité électromagnétique Our thyristor unit has an excellent immunity to electromagnetic interferences if all suggestions contained in this manual are respected In...

Page 7: ...d compared with power demand from controller the error signal is used to automatically hold the power at demanded level 1 4 What is a thyristor unit A thyristor unit is semiconductor device which acts as a switch formed by two thyristors in antiparallel To switch on the alternating current the input signal will be on and the thyristor will switch off at first zero crossing voltage with no input si...

Page 8: ...ng Burst Firing DT BF Phase Angle PA Auxiliary voltage supply 230 à 200 230V 15 10 VA power consumption 460 à 300 460V 15 10 VA power consumption Fan voltage supply 230V 15 110V 15 On request Fuses Internal Heather break alarm Discrimination better than 20 Circuit microprocessor based to diagnose partial or total load failure and short circuit on Thyristors Latching alarm plus reset Relay output 0...

Page 9: ...0 5250 15 128000 47 70 320 2500 400 24 600 1200 1600 200 7800 15 300000 47 70 397 2500 500 24 600 1200 1600 200 8000 15 306000 47 70 530 2500 600 24 600 1200 1600 1000 17800 15 1027000 47 70 589 2500 700 24 600 1200 1600 1000 17800 15 1027000 47 70 712 2500 2 4 Derating curve 1 0 8 0 6 0 4 0 2 0 45 55 65 75 85 K C I I x K NOM MAX 2 5 Fans The thyristor units are equiped with a fan The fan supply m...

Page 10: ... the load is 24V 4 Auxiliary Voltage 230V 200 230V 15 10VA 460V 300 460V 15 10VA 600V 600V 15 10VA on request 5 Input SSR 4 30VDC 0 10V 0 10V analog input 4 20mA 4 20mA analog input 10K pot Potentiometer 6 Firing ZC Zero Crossing SC Single Cycle BF Burst firing Specify the number on ON cycles at 50 of power S BF Soft Start Burst Firing PA Phase Angle Soft Start and feedback in voltage are not avai...

Page 11: ...ns regarding the factory settings of the unit This label is on the board inside the unit as represented below 4 2 Installation CD3000M unit should be always mounted in vertical position to improve air cooling on heatsink Maintain minimum distances in vertical and in horizontal as below represented Don t install in proximity of hot elements and near units generating electromagnetic interferences Wh...

Page 12: ... 700A Honeywell 11 www honeywell com imc 4 3 Dimensions Size W mm H mm D mm 125A S9 116 316 187 150A S9 116 316 187 200A S9 116 316 187 300A S12 137 520 270 400A S12 137 520 270 500A S12 137 520 270 600A S12 137 520 270 700A S12 137 520 270 ...

Page 13: ...00A User s Manual www honeywell com imc 12 4 4 Fixing Holes A B C Size A mm B mm C mm 125A S9 96 290 104 150A S9 96 290 104 200A S9 96 290 104 300A S12 97 495 97 400A S12 97 495 97 500A S12 97 495 97 600A S12 97 495 97 700A S12 97 495 97 ...

Page 14: ...3000M unit has isolated heatsink For safety connect the heatsink to hearth using its terminal with hearth symbol CD3000M can be susceptible to airborne interferences from near equipment or from interferences on main supply so a number of precautions must be taken Contactors coils and chokes must have in parallel a RC filter and must be supplied with a different voltage line All input output signal...

Page 15: ...nted 7 Reset 8 Reset 9 Input command signal 4 20mA 0 10V SSR 10 Input command signal 4 20mA 0 10V SSR 11 Volt GND 12 Output 8Vdc stabilized 1mA max 13 Output command signal to CD3000 slave 14 Output command signal to CD3000 slave 15 External HB Calibration command 24 Vdc max 16 External HB Calibration command 24 Vdc max 17 Used for the future 18 NC HB relay alarm coil not energized 19 Common relay...

Page 16: ... 15 www honeywell com imc 5 1 2 Power Terminals Before connect or disconnect make sure that the power control cables and wires are insulated from the voltage Terminal Description L2 Line Input T2 Load Output S9 power connection S12 power connection T2 L2 ...

Page 17: ...ng detail Use 75 C copper CU conductor only provided with the terminal type indicated below Current courant Torque couple Lb in N m Wire Range cable Wire Terminal terminal 125A 150A 200A 265 30 1 3 0 Polymeric Terminal Block M8 300A 400A 500A 600A 700A 505 57 0 Bus Bar Bus Bar Adapter M10 ...

Page 18: ...2 x 70 2 x 1 0 M10 2 x 70 2 x 1 0 M10 400A 2 x 95 2 x 3 0 M10 2 x 95 2 x 3 0 M10 500A Bus Bar 60 x 4 mm Bus Bar 60 x 4 mm 600A Bus Bar 60 x 5 mm Bus Bar 60 x 5 mm 700A Bus Bar 60 x 6 mm Bus Bar 60 x 6 mm Auxiliary connectors and earth Current Auxiliary Supply Earth Cable Cable mm2 AWG mm2 AWG Screw M 125A 0 50 18 16 6 M6 150A 0 50 18 16 6 M6 200A 0 50 18 25 4 M8 300A 0 50 18 50 1 M8 400A 0 50 18 5...

Page 19: ...5A to 700A User s Manual www honeywell com imc 18 5 2 1 Serial Communication Terminals 5 1 6 9 Pin 1 PMS5 5V Pin 2 GND 0V Pin 3 GND 0V Pin 4 Reserved Rxd0 Pin 5 GND 0V Pin 6 RS485 Pin 7 RS485 Pin 8 nc Pin 9 Reserved Txd0 RS485 B A ...

Page 20: ...ON 24 V dc INPUT POT 10 Kohm T2 NOTE IMPORTANT The user installation must be protected by electromagnetic circuit breaker or by fuse isolator The auxiliary voltage supply must be connected as above and must be syncronized with load voltage power supply L1 L2 If the auxiliary voltage written on the identification label is different from supply voltage to the load use an external transformer as repo...

Page 21: ...5 4 LED Status Table LED STATUS DESCRIPTION PW green led Auxiliary supply is not connect Auxiliary supply is connect ON green led OFF Condition Load IS NOT Powered ON Condition Load IS Powered SC red led SCR OK SCR short circuit HB yellow led Laod OK Load Fault Light OFF Light ON ...

Page 22: ...han nominal verify that all auxiliary connections are right and syncronized to main voltage Fan voltage equal than nominal 230V std 120 optional After which supply thyristor unit giving the maximum input signal and verify that load current is equal or less than thyristor unit nominal current Warning this procedure can be done just by specialized personnel The thyristor unit is delivered configured...

Page 23: ...J10 as shown below 460V Auxiliary supply To set the auxiliary power supply to 460V close J10 and open J9 and J11 as shown below 600V Auxiliary supply This is a special version on request In this case the unit is supplied already configured J11 J10 J9 J11 J10 J9 J11 J10 J9 If the Auxiliary Voltage written on the identification label is different from Supply Voltage to the load use an external trans...

Page 24: ... change on site the configuration procede as specified To change input type open cover and configure jumpers as represented below Warning this procedure can be done just by specialized personnel Location of auxiliary supply jumpers for S9 size Location of auxiliary supply jumpers for S12 size Jumpers Configuration MAIN PCB Input J7 J16 J17 SSR A B C A B C A B C 0 10V A B C A B C A B C 4 20MA A B C...

Page 25: ...flashing yellow and red leds Within 10 sec from start flashing yellow and red leds push again momentary CAL Key Yellow led only is flashing apply 0 input Signal I E 0V for 0 10V 4mA for 4 20mA Red led only is flashing apply 10V for 0 10V input or 20mA for 4 20mA input Now press CAL Key again Now press CAL Key again The leds will stop flashing Release key when red and yellow led are ON Yello and re...

Page 26: ... unit size The current trasformers are internal to the unit Minimum current readable is 10 fo nominal current of the thyristor unit 6 2 1 Heater Break Alarm indication The Heater Break status is displayed with a relay and two leds as the following table SC red led SCR OK SCR short circuit HB yellow led Laod OK Load Fault light OFF light ON 6 2 2 H B Relay The contact of the H B Relay is available ...

Page 27: ...e Calibration procedure verify that connections are correct supply the thyristor unit push CAL button on front of the unit for S9 or on the PCB board for S12 or supply with 24Vdc terminals 15 and 16 or send command via RS485 the thyristor unit goes in conduction state to measure load current all LEDS are ON this means that calibration procedure is active after one minute LEDS for H B and S C switc...

Page 28: ...RELAY OUTPUT T2 T2 EXTERNAL HB CALIBRATION 24 V dc Reset Push Button normally closed Reset Push Button normally closed 6 2 6 RS485 Command HB calibration RS485 BUS If load current decreases for partial or total load failure sensitivity 20 standard Adjustable via RS485 the yellow LED becomes ON and alarm relay changes status If CD3000M is still in conduction with no input signal LED green OFF it me...

Page 29: ...PCB board is switched ON the unit starts in phase angle for 1 sec after witch it switches OFF when the supply waveform is negative and starts again when it s positive giving a delay on triggering signal on first halt positive cycle This technique avoids to have fuse blowing If circuit board is maintained under voltage phase angle start is not used To enable delay triggering option remove plastic c...

Page 30: ... when the sum of rest is one the unit deliveries one cycle more to the load With this firing is necessary to have analog input VOLTAGE SUPPLY V 20 50 70 100 7 3 Burst Firing BF This firing performed in Digital mode in Honeywell Thyristor unit gives a lot of advantages because switches Thyristor at zero voltage crossing without EMC interferences Analog input is necessary for BF and can be decided h...

Page 31: ...hes OFF when the supply waveform is negative and starts again when is positive giving a delay on triggering signal on first halt positive cycle If circuit board is maintained under voltage phase angle start is not used LINE VOLTAGE T V LOAD SUPPLY T 7 6 Phase Angle PA With Phase Angle is possible to control the power to the load allowing to Thyristor to be in conduction for a variable part of the ...

Page 32: ...om imc 7 7 Configurator To configure CD3000M unit you can download the free software and the Configurator Manual from our web site www honeywell com imc To configure the unit you can use the standard communication on RS485 port or use a programming cable with K11 connector ...

Page 33: ...Honeywell CD3000M 1PH from 125A to 700A User s Manual www honeywell com imc 32 7 7 1 RS485 standard communication port If you use this port you must have a RS232 485 converter 5 1 6 9 RS485 B A ...

Page 34: ...ser s Manual CD3000M 1PH from 125A to 700A Honeywell 33 www honeywell com imc 7 7 2 Programming via K11 connector If you use the K11 connector you need the special programming cable supplied by Honeywell ...

Page 35: ...t ARMS I t A2 sec Vac 125A 200 FEE 200 11400 660 6 6 URY 000 BS88 200 200 16000 660 150A 200 FEE 200 11400 660 6 6 URY 000 BS88 200 200 16000 660 300A 350 FM 350 105000 660 6 6 URZ 000 BS88 Z 350 350 85000 660 400A 550 FMM 550 215000 660 6 6 URZ 000 BS88 Z 550 550 208000 660 500A 700 FMM 700 420000 660 6 6 URZ 000 BS88 Z 700 700 340000 660 600A 2x 450 FMM 450 105000 660 6 6 URZ 2x000 BS88 Z 450 2X...

Page 36: ...Word 03 Preset Multiple Registers Write n Word 16 The Controller will identify itself in response to a Read Holding Registers message which enquires the values of word parameters 121 and 122 see Table 4 2 MODBUS Function 17 Report Slave ID is not supported 9 2 1Message Formats The first character of every message is the Controller address in the range 1 255 and 0 for broadcast messages The second ...

Page 37: ...ividing polynomial is 216 215 22 1 Hex 18005 but this is modified in two ways because the bit order is reversed the binary pattern is also reversed making the most significant bit MSB the right most bit because only the remainder is of interest the right most most significant bit can be discarded Thus the polynomial has the value Hex A001 9 2 2 Bit s order Normal bit order Most significant bit Lea...

Page 38: ...J CR is shifted by 1 bit to right Added 1to J Added 1 to I END After shifting CR by 1 bit to right A001 Hex and exclusive logical sum XOR are executed for setting the result in CR Bit at right and of CR is 1 NO NO NO YES YES YES Eight times of calculation is completed J 8 Calculation of all charactersis completed I All characters numbers Exclusive logical Sum XOR is executed on one character 1 byt...

Page 39: ... Controller to obtain the value of one or more registers comprises the following eight bytes Addr unit Func Address 1 word N of Word CRC 16 3 3Hex HI LO HI LO HI LO The normal reply will echo the first two characters of the message received followed by a single byte data byte count which will not include itself or the CRC For this message the count value equals the number of parameter values read ...

Page 40: ...er parity check failure framing error etc or if the CRC16 check fails or if the received message is otherwise syntactically flawed e g byte count or word count is incorrect the thyristor will ignore that message If the received message is syntactically correct but nonetheless contains an illegal value the thyristor will send a five byte exception response as follows Addr unit Func N Exception CRC ...

Page 41: ...1in Command table i 1 0 0 FF 100 Power Adjust 0 FFH 6 Read Write if BIT1in Command table i 1 0 0 FF 100 9 3 1 Heater nominal current Parameter 1 Operation Read Meaning It correspond at one value in points 0 255 0 FF Hex It represents average current value flowing into thyristors Value depends on current transformer ratio that is different from one size to the other one see below table Nominal curr...

Page 42: ...arameter 124H This value depend on nominal current of transformer that change in function of thyristor nominal current as described in below tab Nominal current A Zero 0 0 Hex A Max 255 ff Hex A 3 5 0 3 5 15 0 25 25 0 25 35 0 50 45 0 50 60 0 100 90 0 100 110 0 100 9 3 3 Status Table Parameter 3 Operations Read Meaning It s a tab in bit that represent the Status of thyristor unit 9 3 4 Comand Table...

Page 43: ...ing It s a value in points 0 255 0 FF Hex It s power set point setted in thirst buffer Example 0 0 0 Hex 50 128 80 Hex 100 255 FF Hex 9 3 6 Power adjust Parameter 6 Operations Read Write Meaning Its a value in points 0 255 0 FF Hex Its a scaling factor of power demand Example 1 0 0 50 128 100 255 Example 2 Output Power 100 Power Limit 100 Power real 100 Output Power 100 Power Limit 50 Power real 5...

Page 44: ...ing Its a status but that represents the short circuit on thyristor 0 OK 1 Short circuit 9 3 7 2 Load Failure Bit 1 Operations Read Meaning It s a bit that represent partial or total load failure 0 OK 1 Load failure 9 3 7 3 On Off Bit 2 Operations Read Meaning It s a bit that represent when input signal is ON 0 Input signal OFF 1 Input signal ON 9 3 7 4 HB Calibration in progress Bit 3 Operations ...

Page 45: ...g It s a bit that starts the HB calibration procedure When this bit is zero start the calibration procedure and reset itself automatically at the end 9 3 8 2 Firing command Bit 1 Operations Read Write Meaning It s a command bit used to switch from analog external command to command via RS485 0 Command of analog input 1 Command of RS485 input 9 3 8 3 On Off Bit 2 Operations Read Write Meaning Its a...

Page 46: ...d write 9 4 1 Password Parameter 123 Operations Write Meaning If properly setted give the access to configuration 9 4 2 Delay triggering Parameter 124L Operations Read Write Meaning It s correspond to a value in points 0 50 0 32 Hex Each step is 0 1msec Range is 0 5msec This parameter is the delay of firig in first half period with respect zero voltage crossing 9 4 3 HB Parameter 124H Operations R...

Page 47: ...ggering 2 4 Phase angle Soft start 9 4 5 Soft start time Parameter 125H Operations Read Write Meaning It s correspond to a value in points 0 255 0 FF Hex Each step is 5msec The unit start in phase angle mode with a ramp starting from zero up to full voltage in a presetted and Adjustable time The time is setted by this parameter Value of this parameter must be less than cycle time For burst firing ...

Page 48: ...h step is 50msec It represent a delay to have HB alarm active When is used soft start this time must be longer than soft start time Par126H x 50msec Par125H x 5msec When zero crossing firing is used must be less than cycle time Par126H x 50msec Par127H x 50msec 9 4 8 Max power for SSR Input Parameter 127L Operations Read Write Meaning It s a value in points 0 255 0 FF Hex When SSR input is used it...

Page 49: ...ex Each step is 50msec Cycle Time Time 20 ON OFF 50 70 100 When single cycle SC and burst firing BF is used must be setted at 240 FO Hex When SSR input is used set at 240 FO Hex When is used zero crossing ZC represents the cycle time ON time OFF time default 60 3C Hex 9 4 10 Number of half periods for DT firing Parameter 128L Operations Read Write Meaning Must be setted at 1 ...

Page 50: ... Address table ID 8 7 6 5 4 3 2 1 ID 8 7 6 5 4 3 2 1 1 X 26 X X X 2 X 27 X X X X 3 X X 28 X X X 4 X 29 X X X X 5 X X 30 X X X X 6 X X 31 X X X X X 7 X X X 32 X 8 X 33 X X 9 X X 34 X X 10 X X 35 X X X 11 X X X 36 X X 12 X X 37 X X X 13 X X X 38 X X X 14 X X X 39 X X X X 15 X X X X 40 X X 16 X 41 X X X 17 X X 42 X X X 18 X X 43 X X X X 19 X X X 44 X X X 20 X X 45 X X X X 21 X X X 46 X X X X 22 X X X...

Page 51: ... X 118 X X X X X 69 X X X 119 X X X X X X 70 X X X 120 X X X X 71 X X X X 121 X X X X X 72 X X 122 X X X X X 73 X X X 123 X X X X X X 74 X X X 124 X X X X X 75 X X X X 125 X X X X X X 76 X X X 126 X X X X X X 77 X X X X 127 X X X X X X X 78 X X X X 128 X 79 X X X X X 129 X X 80 X X 130 X X 81 X X X 131 X X X 82 X X X 132 X X 83 X X X X 133 X X X 84 X X X 134 X X X 85 X X X X 135 X X X X 86 X X X X...

Page 52: ...X X X 173 X X X X X 223 X X X X X X X 174 X X X X X 224 X X X 175 X X X X X X 225 X X X X 176 X X X 226 X X X X 177 X X X X 227 X X X X X 178 X X X X 228 X X X X 179 X X X X X 229 X X X X X 180 X X X X 230 X X X X X 181 X X X X X 231 X X X X X X 182 X X X X X 232 X X X X 183 X X X X X X 233 X X X X X 184 X X X X 234 X X X X X 185 X X X X X 235 X X X X X X 186 X X X X X 236 X X X X X 187 X X X X X ...

Page 53: ...ith HB option the yellow led HB in light on condition Substitute the fuse Repair the load Provide to repair the wiring Substitute the faulty thyristor Check the load Load current flows also with no input signal Green LED ON always in light off condition Short circuit on thyristor If there is HB circuit the red LED SC is light on Substitute the thyristor Check that load is not in short circuit Curr...

Page 54: ...erature falls below the setted value This means that also with input signal in ON condition the unit is switched OFF and the system can not work at full power For these reason is important to control periodically the fan status checking that is rotating 10 4 Servicing In order to have correct cooling the user must clean the heatsink and the protective grill of fan The frequence of this servicing d...

Page 55: ...Honeywell CD3000M 1PH from 125A to 700A User s Manual www honeywell com imc 54 ...

Page 56: ... Honeywell during the period of coverage Honeywell will repair of replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as o...

Page 57: ...9 806497336 Hungary Honeywell Kft Phone 36 1 451 4335 FAX 36 1 451 4343 Italy Honeywell S p A Phone 39 02 9214 6503 FAX 39 0292146377 The Netherlands Honeywell B V Phone 31 0 205656999 FAX 31 0 165330746 Norway Honeywell A S Phone 45 39 55 55 55 Poland Honeywell Sp zo o Phone 48 22 6060900 FAX 48 22 6060901 Portugal Honeywell Portugal Lda Phone 351 21 424 5000 FAX 351 21 424 50 99 Romania Honeywel...

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